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equipment  damage due to explosion, 
fire, extreme cold or chemical attack. 

 
 
Never  operate  a  pump  which  is  pumping 
hydrocarbons or other flammable, hot, cold, 
or  corrosive  fluids  when  any  part  of  the 
pump,  suction  system  or  discharge  system 
is  leaking.    Stop  the  pump  immediately  if 
any  leakage,  other  than  a  few  drops  per 
minute  of  packing  weepage,  is  observed.  
Keep  all  flame,  sparks,  or  hot  objects  away 
from  any  part  of  the  pump,  suction  system, 
or  discharge  system.    Shield  the  pump, 
suction  system  and  discharge  system  to 
prevent  any  flammable,  hot,  cold  or 
corrosive  fluid  leakage  from  dripping  or 
spraying on any components, flame, sparks, 
hot objects or people.  Inspect the plungers, 
packing, gaskets and seals for fluid leakage 
frequently  and  replace  all  worn  or  leaking 
parts. 
 
Selection  of  the  proper  gaskets,  seals  and 
stuffing  box  packing  is  even  more  critical 
when  flammable,  hot,  cold  or  corrosive 
fluids  are  being  pumped  than  when  other, 
inherently  less  dangerous  fluids  are  used.  
Contact 

Gardner 

Denver 

service 

representative  for  assistance  in  selecting 
the  proper  gaskets,  seals  and  packing 
before beginning operation. 
Since  some  packing  weepage  into  the 
cradle  area  is  inevitable,  a    drain  located 
below  the  bottom  of  the  cradle  must  be 
connected to a drain line which conducts the 
fluid  leakage  to  a  collection  container 
located  in  a  protected  area.    The  entire 
drain  system  and  container  must  be 
constructed  of  materials  resistant  to  attack 
from  the  pumped  fluid  or  from  explosion  or 
fire  of  the  pumped  fluid.    Heavy  duty 
cradle  covers  must  be securely fastened 
in the proper position on the pump at all 
times when the pump is operating.  If the 
pumped fluid releases harmful, explosive 
or  flammable  vapors  the covers must be 
vented  to  conduct  the  fumes  away  from 
the pump unit to a non-hazardous area. 
 
Before  beginning  pumping  operations  or 
starting the pump power source (whether an 
engine  or  electric  motor)  check  the 
atmosphere  all  around  the  pumping  site  for 

the  presence  of  flammable  or  explosive 
vapors.    Do  not  begin  operation  and  stop 
ongoing operation if flammable or explosive 
vapors  are  detected.    Hot  surfaces,  sparks, 
electric  current  or  engine  exhaust  could 
ignite flammable or explosive vapors.  Each 
engine used as a power source on pumping 
units  where  flammable  or  explosive  vapors 
could  form  should  be  equipped  with  an  air 
inlet  shut-off.    If  flammable  or  explosive 
vapors  are  present  in  the  pumping  site 
atmosphere,  an  engine  could  continue  to 
run  on  these  vapors  even  after  the  engine 
fuel  line  is  shut-off  if  an  air  inlet  shut-off  is 
not used. 
 
In  addition,  on  pumping  units  used  where 
flammable  or  explosive  vapors  could  form, 
all  electric  motors  used  as  power  sources 
must be of explosion proof construction and 
all  electrical  components  and  wiring  must 
meet  the  current  National  Electrical  Code 
for explosive atmospheres. 
 
These  precautions  must  be  taken  to  avoid 
possible  personal  injury,  death  and/or 
equipment  damage  from  explosion,  fire  or 
burns. 
 
HIGH PRESSURE LIQUID JETTING, 
BLASTING AND CLEANING
  
 
 

 

DANGER 

 

Extreme caution must be exercised if 
any type of wand, gun, nozzle or any 
other  pressure  and  flow  directing 
device  is  attached  to  the  pump 
discharge  system  for  use  in  jetting, 
blasting,  cleaning,  etc.    This  type  of 
equipment  must  be  used  by  trained, 
experienced 

operators 

with 

the 

utmost  care.    High  pressure  fluid 
streams  can  either  by  direct  contact 
or by propelling loose objects, cause 
serious  personal  injury  or  death  to 
operators and/or other persons. 

 
 

Summary of Contents for HD-2250

Page 1: ...ECN 1058968 GARDNER DENVER 300THD996 Revision D April 2011 HD 2250 TRIPLEX PUMP OPERATING AND SERVICE MANUAL...

Page 2: ...n pump maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your local authorized Gardner Denver distributor ref...

Page 3: ...tion and minimal downtime DANGER Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Warn...

Page 4: ...s For Ordering Repair Parts i Foreword ii Index iv List of Illustrations v Section 1 Danger Notices 1 Section 2 Design Description and Specifications 9 Section 3 Preparation Operation and Maintenance...

Page 5: ...Performance Rating HD 2250 13 Periodic Routing Maintenance Schedule 18 Plunger Packing Lubrication 16 Plunger Packing Lubrication Recommendation Chart 19 Plungers and Packing Replacement 21 Power End...

Page 6: ...10 Figure 2 3 HD 2250 Power End Section B B 11 Figure 2 4 Fluid End 12 Figure 3 1 Power End Lubricant Recommendations 16 Figure 4 1 Fluid End Stay Rods and Heavy Hex Nuts 21 Figure 4 2 Packing Assemb...

Page 7: ...when operating high pressure pumping equipment Operators should not begin or continue operations when tired distracted or under the influence of alcohol or any type of prescription or nonprescription...

Page 8: ...od condition Replace any of those parts which are cracked damaged or badly worn Wear safety shoes and goggles Check to insure they have safe footing Fully engage the wedge to prevent it from disengagi...

Page 9: ...lders Package units should be lifted with spreaders connected to the lifting attachments normally built into the package unit support skid Packages too large to lift as fully assembled should be separ...

Page 10: ...rect pressurized relief flow to another location such as a collecting tank is not blocked The discharge system is not blocked and all the discharge line valves are open Check all fluid end discharge s...

Page 11: ...trols are clearly tagged with warnings not to start the pump while repair work is in process Whenever the pump is operating continually monitor the entire suction discharge and pump lubricating system...

Page 12: ...ng If the pumped fluid releases harmful explosive or flammable vapors the covers must be vented to conduct the fumes away from the pump unit to a non hazardous area Before beginning pumping operations...

Page 13: ...e liquid jetting blasting or cleaning devices the operators must always wear protective clothing including but not limited to a hard hat with full face visor heavy duty rain coat and pants boots with...

Page 14: ...orated in their products After careful study of various manufacturers products we recommend that only those wands nozzles guns connections and hose etc be considered for purchase that you judge to off...

Page 15: ...FIGURE 2 1 HD 2250 PUMP Page 9...

Page 16: ...eloped by American Gear Manufactures Association The HD 2250 has a proven track record as a reliable trouble free pump The Issue of personnel safety is the most important topic covered in this manual...

Page 17: ...pump will vary slightly due to the various accessories but will not exceed 12 650 pounds Materials used in the power end have been selected to provide long life and meet the rigorous demands required...

Page 18: ...bit coating for improved break in characteristics The wrist pin which is made of heat treated ground high strength alloy steel serves only to return the crosshead assembly It bears none of the thrust...

Page 19: ...d There is one drain hole on the bottom of the power frame User plumbing will direct drain oil flow back into the lube sump FLUID END FIGURE 2 4 The conventional valve over valve configuration offers...

Page 20: ...50 1 65 165 14941 248 14010 330 10508 545 6368 4 00 1 31 130 18909 196 17732 261 13299 431 8060 3 75 1 15 115 21515 172 20175 229 15131 378 9170 Brake Horsepower 1600 2250 2250 2250 Based on 90 Mechan...

Page 21: ...g or tape the opening 6 Coat the gear reducer input shaft and all exposed bare metal with a heavy rust preventive 7 Plug drain holes at the bottom of the pump frame at the rear of the pump and the gea...

Page 22: ...ore the following guidelines developed as a result of long experience should be adhered to closely 1 The oil flow velocity through the suc tion piping should not exceed 2 ft sec or 0 6 m sec 2 At maxi...

Page 23: ...The first startup is performed at the factory during the acceptance tests as a part of quality assurance procedure However the new pump break in period process may continue for the first 80 100 hours...

Page 24: ...page 12 11 During this time observe the suction vacuum gage reading oil pressure and temperature and check for leaks 12 Run the pump at 80 90 strokes per minute at the following loads 40 of full rated...

Page 25: ...ndicate the need for fluid end maintenance such as changing valves or valve seats Due to very high pressures in the triplex pump fluid end worn valves and seats should be changed as soon as possible t...

Page 26: ...etroleum EP 500 Summer or EP 300 Winter 10 F Shell Oil Co Torcula Oil 32 50 F Torcula Oil 100 20 F Torcula Oil 150 15 F Torcula Oil 320 10 F Sun Oil Co Rockdrill 500 Light 5 F Rockdrill 1000 Heavy 5 F...

Page 27: ...and lifting devices should be used while working on pump FLUID END SERVICE This discussion starts with the description of steps necessary for removal and installation of the fluid cylinder assembly a...

Page 28: ...Cylinder Head sequence These nuts must be kept tight Under torqued nuts will lead to thread fatigue failure of the stay rods 6 Re install the plunger clamps piping connections and auxiliary equipment...

Page 29: ...4 to 5 1 4 7 16 5 1 2 to 6 3 4 1 2 7 larger 5 8 Movement tolerance 1 16 SuperBolt Style Covers Removal Jackbolts must be unloaded gradually If some jackbolts are unloaded prematurely the remaining ja...

Page 30: ...he suction cover retainer nut with the appropriate male hex wrench 2 Remove the suction cover with a threaded slide hammer type puller 3 If equipped open the hinged cover on the top of the crosshead h...

Page 31: ...e performed with the fluid cylinder on the pump Before starting make sure that special tools required for this procedure are available For part number of the tools see Parts Manual WARNING Never try t...

Page 32: ...emove the plunger clamps and slide the plungers forward 4 Remove the Oil Stop Head retainer cap screws and remove the Head 5 Remove roto seals and oil hoses from gear covers 6 Remove input seal housin...

Page 33: ...The crosshead guides or slide should be replaced if excessively worn or damaged See CLEARANCES pg 33 2 If the crosshead guides must be replaced it is recommended that it be done either by Gardner Den...

Page 34: ...hould come up and over the top of the pump out to the centerline for easy balanced lifting of the crankshaft This tool must be capable of lifting the crankshaft in a horizontal position 8 The cranksha...

Page 35: ...against the bearing race as severe damage to the bearings could occur WARNING When reassembling the crankshaft assembly make sure to follow these steps 1 Pack the outer races in dry ice before assemb...

Page 36: ...ogged suction line 3 Clean out line 4 Suction and or discharge 4 Remove the obstruction valves propped open Low Discharge Pressure 1 Worn or fluid cut valve 1 Replace valve assembly 2 Valve propped op...

Page 37: ...tling time in supply tank Reduce pump speed 10 Air entering suction line 10 Repair suction line 11 Air entering charging pump 11 Tighten or replace shaft packing or seal 12 Air entering or charge gas...

Page 38: ...transmitted to 11 See Excessive Valve power end Noise problem 12 Cavitation noise transmitted 12 See Cavitation Fluid to or causing shock loading in Knock or Hammer problem power end Excessive Valve N...

Page 39: ...sealing surface 4 Corrosion due to wrong 4 Determine and install correct stuffing box material stuffing box for pumped fluid 5 Stuffing box bore worn 5 Replace stuffing box Pumped Fluid In 1 Worn dam...

Page 40: ...Customer Service 5 Wrong size packing 5 Install correct size packing 6 Improper packing installation 6 Check installation procedure and install correctly 7 Excessive crosshead wear 7 Replace crosshead...

Page 41: ...mmer problem Stud Failures 1 Catastrophic failures 1 See Catastrophic Failures problem 2 Improper nut torquing 2 Check torque specifications and torque to correct values 3 Stud bending due to uneven 3...

Page 42: ...bled in Bearing Housing 7 254 7 259 Crosshead Guide Bore 9 877 9 880 Crosshead OD 9 860 9 855 Wristpin Dia 2 500 2 499 Wristpin Bushing Bore 2 503 2 505 RECOMMENDED RUNNING CLEARANCES ACTUAL New in Ma...

Page 43: ...sing 3 4 10 160 Extension Rod to Crosshead 3 1 4 8 1200 Conn Rod to Bearing Housing Lock Nuts 7 8 9 340 Fluid End Suction Manifold 7 8 9 340 Discharge Flange to Fluid Cylinder Nuts 1 8 475 Conn Rod Be...

Page 44: ...anty Period for all products is 1 250 hours of operation or three 3 months after start up not to exceed 120 days after delivery to Purchaser whichever occurs first The exceptions are as follows 1 Powe...

Page 45: ...regoing warranty is the sole and exclusive warranty of the Company The Company hereby extends other manufactures warranty or guaranties if any given to Company by such manufacturer but only to the ext...

Page 46: ...o this warranty shall not be construed as an admission by the Company that any product was not as warranted WARRANTY REQUESTS Products to be returned for warranty analysis shall be approved for return...

Page 47: ...representative or Gardner Denver Inc 4747 South 83rd East Avenue Tulsa OK 74145 PH 918 664 1151 800 637 8099 FAX 918 664 6225 www gardnerdenver com Specifications subject to change without notice Cop...

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